Basket type carrier,blank therefor and method of loading the carrier



R. J. HICKIN Dec. 1, 1970 3,543,472 BASKET TYPE CARRIER, BLANK THEREFOR AND METHOD OF LOADING THE CARRIER 3 Sheets-Shet 1 Filed Feb. 23, 1968 will.

R. J. HICKIN 3,543,47 BASKET TYPE CARRIER, BLANK THEREFOR AND METHOD OF Dec. 1, 1970 LOADING THE CARRIER 7. Filed Feb. 23, 1968 Dec. 1, 1970 R.J. HICKIN 3,543,472

BASKET TYPE CARRIER, BLANK THEREFOR AND METHOD OF LOADING THE CARRIER Filed Feb. 23, 1968 3 Sheets-Sheet 5 States 3,543,472 BASKET TYPE CARRIER, BLANK THEREFOR AND METHOD OF LOADING THE CARRIER Robert J. Hiekin, Seville, Ohio, assignor to Packag ng Corporation of America, Evanston, 111., a corporation of Delaware Filed Feb. 23, 1968, Ser. No. 707,782 Int. Cl. B651 21/14 US. Cl. 53-35 Claims ABSTRACT OF THE DISCLOSURE BACKGROUND OF THE INVENTION Heretofore basket type carriers used in the merchandising of bottled beverages have been of complex design and by reason thereof have been costly and difficult to set up. Furthermore, because of certain structural weaknesses inherent in the prior carrier designs, it was oftentimes necessary to utilize heavier fibreboard stock or to utilize independent reenforcing pieces which required separate operations to apply to the carrier blank or to the carrier after it had been partially or fully set up.

Where full cell protection was required in prior carriers, it was generally obtained only at the structural sacrifice of some other part of the carrier or by the utilization of various separate inserts. Furthermore, the prior carriers were not capable of readily accommodating articles, the number and shape of which might vary over a wide range, without the carrier design undergoing substantial structural modifications.

Prior carrier designs also required top loading thereof which frequently presented problems where the loading was done by automatic or semi-automatic equipment. In addition, such top loading operations were relatively slow, awkward, and oftentimes required special and costly article-handling equipment.

SUMMARY OF THE INVENTION Thus, it is one of the objects of this invention to provide a carrier, a blank therefor, and a method of loading same which readily overcomes the problems associated with prior carriers of this general type.

It is a further object of this invention to provide a carrier which may utilize thinner and less expensive fibreboard stock without sacrificing structural strength and stability of the carrier.

It is a further object of this invention to provide a full cell carrier of one piece construction which embodies broad surface areas on which attractive and fanciful indicia can be readily imprinted.

It is a further object of this invention to provide a carrier and method of loading same which utilizes many of the techniques and procedures well known in the folding carton art.

It is a still further object of this invention to provide a basket carrier blank which is of simple design, results in a minimum of fibreboard waste, and can be produced on high speed equipment of conventional design.

3,543,472 Patented Dec. 1, 1970 It is a still further object of this invention to provide a method of loading a carrier which is expeditious and minimizse bottle handling thereby reducing to a marked degree the incidences of bottle breakage even though thin-walled non-returnable glass bottles are involved.

Further and additional objects will appear from the description, accompanying drawings and appended claims.

In accordance with one embodiment of this invention a basket type carrier is provided which is formed from a single blank of fibreboard material prefolded to form a tubular member. The carrier includes a pair of sections, each comprising wall panels and closure flaps which cooperate to form an article-accommodating compartment closed at the bottom and open at the top. A corresponding wall panel of each section is connected to one another along the upper edge thereof by a common foldline. The interconnected corresponding wall panels of the sections are adapted to initially form a side of the tubular member. The section closure flaps are initially in unfolded condition and disposed at opposite ends of the tubular member whereby a plurality of articles may be readily loaded endwise through the tubular member opposite ends. Subsequent to the tubular member sections being end loaded, the closure flaps are folded into overlapping relation whereupon the loaded sections are pivoted relative to one another about said common foldline into upright face-to-face relation.

For a more complete understanding of the invention, reference should be made to the drawings wherein:

FIG. 1 is a plan view of one form of a blank for the improved carrier;

FIG. 2 is similar to FIG. 1 but with the blank in a partially folded condition whereby adhesive may be readily applied to predetermined areas of the blank;

FIG. 3 is similar to FIG. 1 but with the blank in a collapsed tubular condition;

FIG. 4 is a perspective end view of the blank set up to form a tubular member ready for end loading;

FIG. 5 is an end elevational view of one end of the tubular member shown in FIG. 4 subsequent to the articles being end-loaded and prior to the closure flaps being folded into overlapping relation;

FIG. 6 is a side elevational view of the tubular number of FIG. 4 loaded with articles and the closure flaps in overlapping relation;

FIG. 7 is a top plan view of FIG. 6;

FIG. 8 is similar to FIG. 6 but showing the loaded carrier sections in partial pivotal relation about a common section-connecting foldline as an axis;

FIG. 9 is similar to FIG. 8 but showing the loaded carrier sections in fully upright face-to-face relation;

FIG. 10 is a perspective end view taken from above of the improved carrier and showing the sections thereof in fully set up condition but empty;

FIG. 11 is a perspective end view taken from below of the carrier of FIG. "10;

FIG. 12 is similar to FIG. 11 but showing a loaded carrier with modified bottom-forming closure flaps; and

FIG. 13 is a fragmentary plan view, on reduced scale, of a blank for a modified carrier embodying the closure flaps shown in FIG. 12.

Referring now to the drawings and more particularly to FIGS. 10 and 11, one embodiment of the improved basket type carrier 20 is shown which is formed from a single blank 21 of foldable sheet material such as paperboard, see FIG. 1. The illustrated carrier 20 is adapted to accommodate a plurality of articles 22 such as six beverage bottles which are arranged in side-by-side relation and form two parallel rows A and B of three bottles each. The improved carrier may take various other shapes than that shown whereby a larger or smaller number of articles may be accommodated.

The illustrated carrier 20 comprises two sections 23 and 24 which are of like configuration. Each section is provided with foldably connected wall panels 25, 26, 27 and 28 and closure flaps 25', 26', 27 and 28' foldably connected to the lower peripheral edges of the corresponding wall panels. Panels 25 and 27 are hereinafter referred to as end wall panels and the remaining panels 26 and 28 are referred to as side wall panels.

The end wall panels, the side wall panels, and the closure flaps of each section cooperate with one another to form an elongated compartment X in which a row A or B of bottles is disposed. The inner side wall panels 28 of the sections 23 and 24 are interconnected along their upper edges by a common foldline 30, see FIG. 1. When the carrier is fully set up, as shown in FIGS. and 11, the section panels 28 are disposed in upright face-to-face relation with respect to one another. The panels 28 are retained in this relative position by suitable adhesive being applied to the contacting surfaces.

Overlying the interconnected upper edges of the panels 28 and extending downwardly therefrom a short distance and overlying the expOsed surfaces of said panels 28 is a handle-reinforcing member 31. As seen in FIGS. 1 and 2, member 31 is provided with an elongated center foldline 32 which is axially aligned with the common foldline 30.

Section panels 28 are provided with handle-forming openings 33 which are disposed adjacent to but spaced from the upper edges of the panels and are in registration with one another when panels 28 are in face-to-face relation. In addition, each panel 28 is provided with a plurality of struck-out tabs 34 which are adapted to be folded outwardly from the panel into the adjacent compartment X and be disposed intermediate adjacent bottles 22 in the row A or B.

It will be noted in FIG. 1 that the blank 21 has a substantially rectangular peripheral configuration and as a result there is but a minimum of waste of fibreboard when the blank is being formed. It is preferred that the blank 21 be formed from a sheet of paperboard which has one surface finished to readily accept printing thereon. The opposite surface of the blank, on the other hand, is normally not finished so as to not readily accept printing thereon. In the illustrated blank 21, panels 25 and 26 are separated by foldline 35, panels 25 and 28 by foldline 36, and panels 27 and 28 by foldline 37; all of: the said foldlines are in parallel relation. Foldably connected to the edge of panel 27 and opposite foldline 37 is a manufacturers glue flap 38.

Handle-reinforcing member 31 has one end thereof foldably connected to an edge of both section panels 28 by a segment 36a of foldline 36. This foldline segment intersects and is perpendicular to the axially aligned foldlines 30 and 32.

The reinforcing member 31, as seen in FIG. 1, is disposed intermediate the panels 25 and 26 of the sections 23 and 24 and is separated therefrom by non-rectilinear cuts 37. A first segment 37a of each cut separates the member 31 from end wall panel 25, a second segment 37b forms a recess 39 in the member 31, and a third segment 37c in combination with segment 37b separates the member 3.1 from side wall panel 26. The recesses 39 are adapted to register with the openings 33 when the carrier is fully set up as seen in FIG. 10. Obviously the handle-reinforcing member 31 may take various other forms from that shown without departing from the scope of the invention. In instances where the load requirements for the carrier are relatively small when compared with the strength of the fibreboard used to make the carrier, the handle-reinforcing member 31 may be omitted entirely in which case the side wall panels 26 and 28 and end wall panels 25 and 27 might be of equal height.

The closure flaps 2528 inclusive, are connected to the corresponding wall panels by segmented foldlines 40. The segmented foldlines 40 are disposed in parallel relation to foldlines and 32.

Extending axially from one end of foldline 30 is a cut 41 which separates the panels 27 of the sections from one another.

FIGS. 2 and 3 show the steps which may be followed in forming the blank 21 with automatic equipment into a collapsed tubular member as seen in FIG. 3. In FIG. 2 the blank 21 is shown in a partially folded condition in which panels 25 and 26 have been folded as a unit about foldline 36 as an axis into overlying relation with respect to panels 27 and 28 whereby the handle-reinforcing member 31 extends laterally in a horizontal direction from one side of the partially folded blank and the manufacturers glue flaps 38 extend laterally in the opposite direction from the opposite side of the blank. With the member 31 and the glue flaps 38 in such positions, the partially folded blank can be readily passed through a conventional straight-line gluing apparatus so as to cause a coating of suitable adhesive to be applied to the upper, or exposed, surface of member 31 and the under, or concealed, surface of the flaps 38.

After the adhesive coats have been applied as indicated, panels 25 and 26 as a unit are returned to their initial positions as seen in FIG. 1. The member 31 is then folded about foldline segment 36a into overlapping bonded relation with respect to section panels 28. Where blank 21 is formed from paperboard having only one finished and printed side or surface, such surface would be the concealed surface of the blank as illustrated in FIG. 1.

Subsequent to member 31 being bonded to panels 28, panels 27 and the glue flaps carried thereby are folded as a unit about foldline 37 so as to overlie panels 28. Panels 26 are then folded about foldline as a unit so as to also overlap panels 25 and 28 whereby the free vertical edges of panels 26 will register with and become bonded to glue flaps 38. The carrier blank, when in a collapsed tubular form, is normally received in such form by the bottler for either immediate loading or for storage. Because of its collapsed condition, the carrier occupies but a minimum of space.

When the collapsed carrier is ready for loading, it is first set up to form a tubular member as seen more clearly in FIG. 4. Where automatic loading apparatus is to be used, the erected tubular member is placed upon a conveyor of suitable size, not shown, so that the longitudinal axis of the tubular member, or the foldlines 3537, inclusive, will be disposed transversely with respect to the direction of movement of the tubular member. Thus, the open ends of the tubular member, delimited by closure flaps 2528, inclusive, face laterally outwardly. In. placing the tubular member on the aforesaid conveyor, care should be exercised so that panels 28 of the sections 23 and 24 form the bottom or supporting surface of the tubular member. The erected tubular member is moved by the aforesaid conveyor to a loading station, not shown, where its forward movement may be interrupted. While the tubular member is at rest at the loading station, the struck-out tabs 34 are automatically pushed upwardly from the panels 28 into the positions shown in FIG. 4. Once the tabs 34 are so positioned, a row of three filled bottles 22, while laying on their sides, is brought into alignment with the respective tubular member open end at which time the three bottles, with their capped ends facing the open end, are moved as a unit through the open end into the tubular member section a sufficient amount so that the bottoms of the bottles are aligned with the respective foldlines 40. Normally, both ends of the tubular member will be loaded simultaneously.

After the bottles are in position, the closure flaps 25- 28' are folded into overlapping relation. Prior to flaps 26 being folded, suitable adhesive may be applied thereto so as to cause a bond between folded flaps 26' and 28' and thus close the ends of the tubular member, see FIG. 6. Once the ends of the tubular member have been closed, the loaded tubular member resumes its forward movement by the conveyor whereupon adhesive is applied to the undersurfaces of panels 28 by any suitable means such as by spraying, rollers, etc.

Subsequent to the application of adhesive to the undersurface of panels 28, the loaded sections 23 and 24 are moved toward one another about foldline 30 as an axis, see FIG. 8, until the coated surfaces of panels 28 make contact with one another whereby the sections 23 and 24 assume upright side-by-side relation, see FIG. 9. The application of the adhesive to panels 28 and the relative pivoting of the loaded sections may occur while the loaded tubular member is at rest or while it is being moved by the conveyor.

FIGS. 12 and 13 disclose respectively a modified carrier 42 and blank 43 therefor. The modification embodied in the carrier 42 and blank 43 involves the closure flaps 44 which are foldably connected to the lower edge of side wall panels 26m. The numbering of the panels of carrier 42 and blank 43 will be the same as in carrier 20 and blank 21 except for the suflix m.

In FIG. 13 it will be observed that a pair of closure flaps 44 and 45 are connected to the lower edge of side wall panel 26m. A foldline 46 connects flap 44 to panel 26m and a foldline 47 connects flap 45 and flap 44. Flap 44 is provided with a plurality of spaced cutouts 48 each of which has a portion 48a thereof extending into flap 45 a short distance. A short slot or slit 50 is also provided for each cutout 48 which extends upwardly a short distance into panel 26m. As noted in FIG. 12, when the carrier 42 is set up, the cutouts 48 are adapted to accommodate a portion of the lower ends 22a of the bottles 22. The slits 50 permit the side wall panel 26m to snugly engage the accommodated bottles 22 when the carrier is loaded during setup, and thus retain the lower ends of the bottles in proper spaced relation.

When the modified carrier 42 is set up, flap 44 on each side of the carrier will extend angularly inwardly and downwardly (e.g. 30 from the vertical) from the lower edge of panel 26m. Flap 45, on the other hand, extends inwardly at approximately 90 with respect to panel 26m and overlies the closure flap 28'm connected to the side wall panel 28m. Flap 45 is retained in overlapping relation With respect to flap 28'm by a suitable adhesive or the like.

It will be noted that the closure flap 25m, which is connected by foldline 40m to the lower edge of end wall panel 25m is narrower than the width of panel 25m by reason of a wide slot 51 formed between flaps 25m and 4445. The inner end 51a of the slot 51 is cut at an angle so as to conform to the angular disposition of the flap 44 when the carrier is set up, see FIG. 12, and thus give the carrier a more attractive appearance.

When using either blank 21 or 43, it is desirable that the grain of the paperboard extends crosswise of the blank, that is to say in a direction parallel to foldline 40 or 40m. With such an arrangement it is found that the side wall panels 26 and 26m and the end wall panels 25, 27 and 25m are possessed of greater resistance to outward flexure when the carrier is loaded. In addition the carrier is provided with greater resistance to endwise impact.

While the carriers which are illustrated are formed from a blank in which both sections are interconnected by a common foldline, the invention in its broadest concept is not limited thereto. If desired, the two sections when in blank form may be independent from one another. In such a construction the individual sections may be set up and loaded prior to the sections being brought into bonded face-to-face relation. Furthermore, the handle-reenforcing member for each section may be con nected to one section blank or the member may be in two similar longitudinal parts with one part on one section blank and the other part on the other section blank.

Where two independent section blanks are utilized, each section may, if desired, be loaded with the bottles prior to said bottles passing through the filler and capping apparatus which are normally found in bottling plants or the like.

Thus, it will be seen that an improved basket type carrier has been provided which is of simple and inexpensive design, is capable of being readily loaded with but a minimum of bottle handling, is capable of providing effective protection for the accommodated bottles and their contents against breakage and harmful light rays, and is capable of being set up and loaded by automatic or semi-automatic apparatus of conventional construction. In addition the improved carrier is possessed of high load-carrying capacity and therefore a lighter weight and less costly paperboard may be utilized.

While several embodiments have heretofore been illustrated and/ or described, further modifications may be made thereto and it is contemplated, therefore, by the appended claims to cover any such modifications as fall within the true spirit and scope of this invention.

I claim:

1. A method of packaging a plurality of articles in a basket type carrier, said carrier being initially preformed as a tubular member with two sections each provided with foldably connected wall panels and closure flaps connected thereto and cooperating therewith to form an article-accommodating compartment closed at the bottom, a corresponding wall panel of each section being interconnected along the top edge thereof by a common foldline, the latter wall panels forming one wall of the tubular member and the closure flaps being initially unfolded and disposed at opposite ends of the tubular member, said method comprising placing the tubular member in a horizontal plane with the interconnected section wall panels forming the tubular member lower surface, inserting articles endwise at opposite ends of the tubular member between the wall panels of the respective section while the section closure flaps are in unfolded relation, folding the closure flaps into overlapping relation so as to close the opposite ends 0 fthe tubular member, and pivoting the loaded sections about the common foldline until said sections assume upright positions and the interconnected wall panels are in face-to-face relation and form a partition between the section compartments.

2. The method of claim 1 comprising loading the articles into the sections simultaneously at opposite ends of the tubular member, and simultaneously folding of the closure flaps of each section into overlapping relation at opposite ends of the tubular member subsequent to the articles being inserted into the sections.

3. The method of claim 1 wherein the articles are capped bottles and each bottle is resting on its side with the capped end thereof assuming a lead position while the bottle is being inserted into the tubular member section.

4. The method of claim 3 wherein a plurality of capped bottles arranged in substantially parallel side-by-side relation are simultaneously inserted as a unit into the adjacent tubular member open end.

5. The method of claim 1 comprising pivoting of the loaded tubular member sections while moving said loaded tubular member in a direction substantially parallel to said common foldline.

References Cited UNITED STATES PATENTS 2,603,924 7/1952 Currie et al. 53-48 2,701,938 2/1955 Murray 5326 2,860,816 11/1958 Fielding 229-28 X 3,359,873 12/1967 Carle et a1. 220102 X TRAVIS S. McGEHEE, Primary Examiner E. DESMOND, Assistant Examiner U.S. C1. X.R. 53-48; 220-113 UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent No. 3, n ,u 2

mums) ROBERT J. HICKIN' Dated December 1, 1970 it is certified that error appears in the above-identified patenl and that said Letters Patent are hereby corrected as shown below:

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